New battery, now no headlight! - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
Where does this wire go?
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post #1 of 8 (permalink) Old 07-15-2019, 05:47 PM Thread Starter
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New battery, now no headlight!

I replaced the aftermarket sealed battery with a new manufacturers suggested wet cell battery in my 2005 (27k miles) because the old battery wouldn't hold a charge. Perhaps R/R or stater problem but haven't tested them yet. New battery installed, runs fine but now I don't have any power to headlight. Must have knocked something loose. Checked every connection I can easily reach. Considering new LED headlight anyway if it's a light problem. Anyhow, scrolling through some threads here revealed typical problems with connectors and boxes, etc. Getting multi-tester soon to check wiring but until then....what can I focus on without wasting too much time/money?
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post #2 of 8 (permalink) Old 07-15-2019, 07:32 PM
2003 Vulcan 750/Sidecar
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Have you done any wiring mods? IE, the RLU wiring mod? If so, could you have possibly knocked the wire/jumper loose?

2003 VN750
Velorex 562 sidecar w/trunk
2-wire mod
Headlight power switch
Manual fan switch
Shingigen SH775
Blue wire mod
Yellow wire mod
RLU removed
RR moved
Voltmeter relay wired
Coils direct wired w/relay
handicap mods:
extended foot shift
heel shifter
extended brake pedal
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post #3 of 8 (permalink) Old 07-15-2019, 09:39 PM
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Check the fuses first.

Check the charging volts, if the stator isn't charging, it may not be tripping the headlight relay.

2003-21k mi
Shaved w/UniPK92+Stock Jets-TPE/MOSFET-Shinko Tires-AGM batt-bags-chrome-LEDs...more
__________________________________________________ ____________
Repair Manual:

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post #4 of 8 (permalink) Old 07-16-2019, 08:52 AM Thread Starter
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Fuses are good. Headlight worked before replacing battery. I haven't done any wiring mods but that doesn't mean previous owner didn't. Everything "looks" stock to me.
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post #5 of 8 (permalink) Old 07-16-2019, 09:32 AM
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You do know the headlight only comes on after the bike has started?

Does the highbeam work?

You can test the headlight by running some wires direct from the battery, or at least use a voltmeter or circuit tester to see if it's getting power.

Also not sure why you'd replace a sealed battery with a wet cell...the exact opposite of what we recommend here.

If You Are Not Sure If I Am Joking or Not....I AM !!Photos:

Last edited by Knifemaker; 07-16-2019 at 09:36 AM.
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post #6 of 8 (permalink) Old 07-16-2019, 11:48 AM Thread Starter
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Yes, I know headlight is supposed to come on after starting bike. I took advice from the local Kawasaki dealer on the battery. I've never done anything like this before (forums or modifying a bike), trying to learn some stuff here. If I can figure out how, I'll post some before/after pics of my bike so you can see what I'm going for.
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post #7 of 8 (permalink) Old 07-16-2019, 11:56 AM Thread Starter
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This is what it looks like so far. It was completely stock when I bought it in April.
My Mods:
Drag bars
Digital Speedo
LED turn signals
Wrapped pipes
Hand built seat
Ammo box "trunk"
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post #8 of 8 (permalink) Old 07-16-2019, 02:37 PM
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Do the "blue wire mod" to see if that will bring your headlight back. You can do it in a temporary fashion by just interlocking the two spade receptacles together. Do your running lights come on?

1992 US-nonCA * tuxedo mod * r/r relocated

Vulcan slang for newcomers
Service Manual Download
Wiring Diagram + annotations * still undergoing revisions, but still more useful than the generic one. Let me know if you find mistakes or think something additional should be added
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